Metal composite production method

ABSTRACT

A metal composite apparatus and a method to produce the metal composite apparatus is disclosed, including placing a metal skeleton inside a mold, the metal skeleton having a skeleton top surface, a skeleton bottom surface, cutouts, and a central bore having a top end and a bottom end; pouring molten white iron into the mold to substantially encapsulate the metal skeleton forming a single piece cast; protecting the top end and the bottom end of the central bore from contact with the molten white iron; and cooling the single piece cast to form the metal composite apparatus having an apparatus top surface and an apparatus bottom surface.

FIELD

The disclosure generally relates to methods for producing metal composites, and more particularly, but not by way of limitation, methods for producing composites of a metal and white iron.

BACKGROUND

The statements in this section merely provide background information related to the disclosure and may not constitute prior art.

In the oil and gas drilling and production industry, viscous aqueous fluids are commonly used in treating subterranean wells, as well as carrier fluids. Such fluids may be used as fracturing fluids, acidizing fluids, and high-density completion fluids. In an operation known as well fracturing, such fluids are used to initiate and propagate underground fractures for increasing petroleum productivity.

During fracturing operations, fluids pumped into the subterranean formation can include solids such as proppant mixed with a fluid such as an aqueous gel. Such proppant-containing fluids are mixed in a blender including a slinger and a pump impeller, each attached to a drive shaft and enclosed within a casing. In recent years, fluids containing elevated levels of solids have been used resulting in substantial increases in wear and tear on the blender internals and resulting in decreased mixing and pumping efficiency. The slinger tends to wear out much faster than the impeller due to its contact with the solids laden fluid while the impeller contacts fluid having much lower solids concentrations. Thus, the slinger portion benefits from harder material which is also more brittle, while the impeller can be made from a strong but more machinable metal. Achieving a cast integrated slinger and impeller design for use in well stimulation is thus challenging due to the need to use the harder and more brittle material necessary for the slinger portion and the related difficulty in machining such metal.

Therefore, there is a need for efficient methods useful for producing a metal composite of a harder material and a strong and machinable material, such need met, at least

SUMMARY

This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify indispensable features of the claimed subject matter, nor is it intended for use as an aid in limiting the scope of the claimed subject matter.

In an embodiment, a method of producing a metal composite apparatus is disclosed including: placing a metal skeleton including metal inside a mold, wherein the metal skeleton has a skeleton top surface, a skeleton bottom surface, cutouts, and a central bore having a top end and a bottom end; pouring molten white iron into the mold to substantially encapsulate the metal skeleton forming a single piece cast; wherein the top end and the bottom end of the central bore are protected from contact with the molten white iron, the melting point of the metal of the metal skeleton is equal to or greater than the melting point of the molten white iron; and cooling the single piece cast to form the metal composite apparatus having an apparatus top surface and an apparatus bottom surface.

In accordance with another embodiment, a metal composite apparatus is disclosed including white iron substantially encapsulating a metal skeleton having a skeleton top surface, a skeleton bottom surface, cutouts, and a central bore; wherein the central bore is not encapsulated with the white iron.

In accordance with another embodiment, a method of producing a slinger and impeller assembly is disclosed including:

-   -   i. producing a slinger by a method including:         -   a. placing a metal skeleton inside a mold, wherein the metal             skeleton has a skeleton top surface, a skeleton bottom             surface, cutouts, a metal skeleton central bore having a top             end and a bottom end, at least two protrusions extending             from the skeleton bottom surface and each having a distal             end positioned below the apparatus bottom surface following             step c;         -   b. pouring molten white iron into the mold to substantially             encapsulate the metal skeleton forming a single piece cast             which is substantially circular at its outer edge; wherein             the top end and the bottom end of the central bore are             protected from contact with the molten white iron; and         -   c. cooling the single piece cast to form the slinger having             a slinger top surface and a slinger bottom surface;     -   ii. utilizing an impeller having an impeller central bore         alignable with the metal skeleton central bore, an impeller         bottom surface, and an impeller top surface having at least two         recesses sized and positioned to receive the distal ends of the         at least two protrusions of the metal skeleton;     -   iii. aligning the metal skeleton central bore with the impeller         central bore, positioning the distal ends of the at least two         protrusions of the metal skeleton into the at least two recesses         of the impeller top surface; and     -   iv. fastening the impeller to the slinger.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain embodiments of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood, however, that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein.

FIG. 1A shows a perspective view of some apparatus embodiments in accordance with the disclosure.

FIG. 1B shows a perspective view of some apparatus embodiments in accordance with the disclosure.

FIG. 1C shows a bottom plan view of the apparatus of Figures lA and 1B.

FIG. 2A shows a perspective view of some apparatus embodiments in accordance with the disclosure.

FIG. 2B shows a perspective view of some apparatus embodiments in accordance with the disclosure.

FIG. 2C shows a perspective view of some apparatus embodiments in accordance with the disclosure.

FIG. 3A shows a perspective view of some apparatus embodiments in accordance with the disclosure.

FIG. 3B shows a perspective view of some apparatus embodiments in accordance with the disclosure.

FIG. 3C shows a side view of some apparatus embodiments in accordance with the disclosure.

DETAILED DESCRIPTION

In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. However, it will be understood by those of ordinary skill in the art that the system and/or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.

Unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by anyone of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

In addition, use of the “a” or “an” are employed to describe elements and components of the embodiments herein. This is done merely for convenience and to give a general sense of the inventive concept. This description should be read to include one or at least one and the singular also includes the plural unless otherwise stated.

The terminology and phraseology used herein is for descriptive purposes and should not be construed as limiting in scope. Language such as “including,” “comprising,” “having,” “containing,” or “involving,” and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited.

Finally, as used herein any references to “one embodiment” or “an embodiment” means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase “in one embodiment” or “in accordance with an embodiment” in various places in the specification are not necessarily referring to the same embodiment.

In accordance with an embodiment, and with reference to FIGS. 1A-1C, metal skeleton 100 can comprise, consist of, or consist essentially of metal, a skeleton top surface 102, a skeleton bottom surface 104, cutouts 106, and a central bore 108 having a top end 110 and a bottom end 112. In accordance with an embodiment, the metal skeleton 100 can further comprise at least two protrusions 114 extending from the skeleton bottom surface 104. In accordance with an embodiment, the metal skeleton 100 can further comprise at least two holes 116 adjacent the central bore 108.

In accordance with an embodiment, and with reference to FIGS. 2A-2C, a method of producing a metal composite apparatus comprises, consists of, or consists essentially of:

-   -   a. placing the metal skeleton 100 inside a mold (not shown);     -   b. pouring molten white iron into the mold to substantially         encapsulate the metal skeleton forming a single piece cast;         wherein the top end 110 and the bottom end 112 of the central         bore 108 are protected from contact with the molten white iron;         and     -   c. cooling the single piece cast to form the metal composite         apparatus 200 (as shown in FIGS. 2A-2C) having an apparatus top         surface 122 and an apparatus bottom surface 124. In accordance         with an embodiment, the metal composite apparatus 200 can be         substantially circular at its outer edge, as shown in FIGS.         2A-2C.

In accordance with an embodiment, the melting point of the metal of the metal skeleton 100 is equal to or greater than the melting point of the molten white iron. In accordance with an embodiment, the metal of the metal skeleton 100 has lower hardness, better machinability and better shock absorption than the white iron in solid form.

In accordance with an embodiment, the metal of the metal skeleton 100 has a Charpy impact energy greater than 15 J or greater than 30 J or greater than 50 J, when measured at −40° C., and the white iron in solid form has a Charpy impact energy of at most 10 J, when measured at −40° C.

In accordance with an embodiment, the metal of the metal skeleton 100 comprises a metal alloy. In accordance with an embodiment, the metal alloy is an alloy steel. In accordance with an embodiment, the alloy steel comprises less carbon than the white iron. In accordance with an embodiment, the alloy steel comprises less than about 0.5 wt % carbon, and the white iron comprises from about 2.0 to about 3.3 wt % carbon and about 23 to about 30 wt % chromium.

In accordance with an embodiment, the white iron has superior wear resistance as compared to the metal of the metal skeleton 100. The melting point of the white iron is about 2000 to about 2500 or about 2300 Fahrenheit.

In accordance with an embodiment, the central bore 108 can be tapered, the metal composite apparatus 200 is a slinger, and the central bore 108 fits onto a vortex mixer shaft (not shown). In accordance with an embodiment, the at least two protrusions 114 extending from the skeleton bottom surface 104 protrude through the apparatus bottom surface 124 following the encapsulation and cooling in steps b and c.

In accordance with an embodiment, ceramic rods 118 can be placed in the at least two holes 116 and, following step b, extend from below the apparatus bottom surface 124 to above the apparatus top surface 122; and the ceramic rods 118 can then be removed from the metal composite apparatus 200. In accordance with an embodiment, the removal of the ceramic rods 118 creates at least two breathing holes 126 (as shown in FIGS. 2A-2C) adjacent the metal skeleton central bore 108 providing a path for air to pass from below the apparatus bottom surface 124 to above the apparatus top surface 122. In accordance with an embodiment, the metal composite apparatus comprises the white iron substantially encapsulating the metal skeleton 100; wherein the central bore 108 is not encapsulated with the white iron.

In accordance with an embodiment, and with reference to FIGS. 1A-3C, a method of producing a slinger and impeller assembly comprises, consists of, or consists essentially of:

-   -   a. producing the metal composite apparatus 200 as described         herein, wherein the metal composite apparatus is a slinger (as         shown in FIGS. 2A-2C and 3C) having an apparatus top         surface/slinger top surface 122, and an apparatus bottom         surface/slinger bottom surface 124;     -   b. utilizing an impeller 300 comprising an impeller central bore         302 alignable with the metal skeleton central bore 108, an         impeller bottom surface 304, and an impeller top surface 306         comprising at least two recesses 308 sized and positioned to         receive the distal ends of the at least two protrusions 114 of         the metal skeleton 100;     -   c. aligning the metal skeleton central bore 108 with the         impeller central bore 302, positioning the distal ends of the at         least two protrusions 114 of the metal skeleton 100 into the at         least two recesses 308 of the impeller top surface 306; and     -   d. fastening the impeller 300 to the metal composite         apparatus/slinger 200.

In accordance with an embodiment, the impeller can be fastened to the metal composite apparatus/slinger 200 by bolts 312. In accordance with an embodiment, the at least two protrusions 114 of the metal skeleton 100 and the at least two recesses 308 are configured to provide a space 310 between the apparatus bottom surface/slinger bottom surface 124 and the impeller top surface 306 allowing air to pass from the space 310 through the breathing holes 126 for escape above the apparatus top surface/slinger top surface 122.

In accordance with an embodiment, the metal skeleton central bore 108 is tapered, the impeller central bore 302 is tapered, and the metal skeleton central bore 108 and the impeller central bore 302 each fit onto a vortex mixer shaft (not shown).

The foregoing description of the embodiments has been provided for purposes of illustration and description. Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the disclosure, but are not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Further, it will be readily apparent to those of skill in the art that in the design, manufacture, and operation of apparatus to achieve that described in the disclosure, variations in apparatus design, construction, condition, erosion of components, gaps between components may present, for example.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,”, “top,”, “bottom,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Although various embodiments have been described with respect to enabling disclosures, it is to be understood the invention is not limited to the disclosed embodiments. Variations and modifications that would occur to one of skill in the art upon reading the specification are also within the scope of the invention, which is defined in the appended claims. 

What is claimed is:
 1. A method of producing a metal composite apparatus comprising: a. placing a metal skeleton comprising metal inside a mold, wherein the metal skeleton comprises a skeleton top surface, a skeleton bottom surface, cutouts, and a central bore having a top end and a bottom end; b. pouring molten white iron into the mold to substantially encapsulate the metal skeleton forming a single piece cast; wherein the top end and the bottom end of the central bore are protected from contact with the molten white iron; the melting point of the metal of the metal skeleton is equal to or greater than the melting point of the molten white iron; and c. cooling the single piece cast to form the metal composite apparatus having an apparatus top surface and an apparatus bottom surface.
 2. The method of claim 1 wherein the metal of the metal skeleton has lower hardness, better machinability and better shock absorption than the white iron in solid form.
 3. The method of claim 1 wherein the metal of the metal skeleton comprises a metal alloy.
 4. The method of claim 3 wherein the metal alloy is an alloy steel.
 5. The method of claim 1 wherein the white iron has superior wear resistance as compared to the metal of the metal skeleton.
 6. The method of claim 1 wherein the metal skeleton further comprises at least two protrusions extending from the skeleton bottom surface and protruding through the apparatus bottom surface following step c.
 7. The method of claim 1 wherein the metal skeleton further comprises at least two holes adjacent the central bore, and wherein ceramic rods are placed in the holes and, following step b, extend from below the apparatus bottom surface to above the apparatus top surface; and wherein the ceramic rods are removed from the metal composite apparatus.
 8. A metal composite apparatus comprising white iron substantially encapsulating a metal skeleton comprising metal, a skeleton top surface, a skeleton bottom surface, cutouts, and a central bore; wherein the central bore is not encapsulated with the white iron.
 9. The metal composite apparatus of claim 8 wherein the metal of the metal skeleton has lower hardness, better machinability and better shock absorption than the white iron in solid form.
 10. The metal composite apparatus of claim 8 wherein the metal of the metal skeleton comprises a metal alloy.
 11. The metal composite apparatus of claim 10 wherein the metal alloy is an alloy steel.
 12. The metal composite apparatus of claim 8 wherein the white iron has superior wear resistance as compared to the metal of the metal skeleton.
 13. The metal composite apparatus of claim 8 wherein the melting point of the white iron is lower than the melting point of the metal of the metal skeleton.
 14. The metal composite apparatus of claim 8 further comprising an apparatus top surface and an apparatus bottom surface; wherein the metal skeleton further comprises at least two protrusions extending from the skeleton bottom surface and protruding through the apparatus bottom surface.
 15. The metal composite apparatus of claim 8 further comprising at least two holes adjacent the central bore and extending from the apparatus bottom surface to the apparatus top surface.
 16. A method of producing a slinger and impeller assembly comprising: i. producing a slinger by a method comprising: a. placing a metal skeleton inside a mold, wherein the metal skeleton comprises metal, a skeleton top surface, a skeleton bottom surface, cutouts, a metal skeleton central bore having a top end and a bottom end, at least two protrusions extending from the skeleton bottom surface and each having a distal end positioned below the apparatus bottom surface following step c; b. pouring molten white iron into the mold to substantially encapsulate the metal skeleton forming a single piece cast which is substantially circular at its outer edge; wherein the top end and the bottom end of the central bore are protected from contact with the molten white iron; and c. cooling the single piece cast to form the slinger having a slinger top surface and a slinger bottom surface; ii. utilizing an impeller comprising an impeller central bore alignable with the metal skeleton central bore, an impeller bottom surface, and an impeller top surface comprising at least two recesses sized and positioned to receive the distal ends of the at least two protrusions of the metal skeleton; iii. aligning the metal skeleton central bore with the impeller central bore, positioning the distal ends of the at least two protrusions of the metal skeleton into the at least two recesses of the impeller top surface; and iv. fastening the impeller to the slinger.
 17. The method of claim 16 wherein the at least two protrusions are positioned such that a space is created between the slinger bottom surface and the impeller top surface.
 18. The method of claim 16 wherein the metal skeleton further comprises at least two holes adjacent the metal skeleton central bore, and wherein ceramic rods are placed in the holes and, following step c, extend from below the slinger bottom surface to above the slinger top surface; and wherein the ceramic rods are removed from the slinger.
 19. The method of claim 18 wherein the removal of the ceramic rods creates at least two breathing holes adjacent the metal skeleton central bore providing a path for air to pass from the space between the slinger bottom surface and the impeller top surface through the breathing holes for escape above the slinger top surface.
 20. The method of claim 16 wherein the metal skeleton central bore is tapered, wherein the impeller central bore is tapered, and wherein the metal skeleton central bore and the impeller central bore each fit onto a vortex mixer shaft. 